Our Build Plan
When we first started this
project, we put together the build plan below. We didn't really want to know how long the whole
thing was going to take, but we did want to know how far along we were at any point in the build.
So this is it. All the gory details. Yes it was a lot of hours, but don't let it discourage you.
We're sure you can build a Locost a lot faster than we did.
Total Build Time:
2228 hours over 116 weeks @ 19 hrs/wkCurrent progress: 2228 hours in 116 weeks, 100% completeCompletion Date: October 3, 2013
Build
Step #1: Cut frame parts
314 hours completed of
314 (100%)
Task
Plan Start
Plan Hrs
Started
Completed
Actual Hrs
Main tubes
2011-08-01
94
2011-08-01
2012-01-05
118
Transmission tubes
2011-09-12
22
2012-01-06
2012-04-27
24
Truss tubes
2011-09-20
12
2012-02-11
2012-02-21
12
Bent tubes
2011-09-24
14
2012-07-06
2012-07-08
6
Aussie tubes
2011-09-27
16
2012-01-08
2012-07-06
10
Suspension brackets
2011-09-30
48
2011-10-17
2011-11-17
44
Shock brackets
2011-10-16
46
2011-12-29
2012-06-22
30
Steering mount
2011-10-26
12
2012-06-06
2012-07-09
12
Engine mounts
2011-10-31
24
2012-07-13
2012-08-05
20
Radiator mount
2011-11-07
12
2012-06-29
2012-07-02
12
Seat belt mounts
2011-11-11
6
2011-11-30
2011-12-04
14
Hand brake mount
2011-11-16
10
2012-03-24
2012-03-25
6
Brake brackets
2011-11-18
4
2012-07-15
2012-07-15
4
Fuel tank mounts
2011-11-20
4
2012-01-09
2012-01-09
2
Build
Step #2: Dismantle donor
110 hours completed of
110 (100%)
Task
Plan Start
Plan Hrs
Started
Completed
Actual Hrs
Remove engine
2011-11-20
26
2012-01-15
2012-03-02
26
Remove interior
2011-11-30
28
2012-02-17
2012-03-12
28
Remove electrical
2011-12-10
24
2012-03-02
2012-03-21
24
Remove fuel lines
2011-12-18
6
2012-03-11
2012-03-23
6
Remove front suspension
2011-12-20
14
2012-03-23
2012-03-24
6
Remove rear suspension
2011-12-22
10
2012-03-23
2012-03-24
8
Remove brakes
2011-12-25
14
2012-03-11
2012-03-24
12
Build
Step #3: Build frame
382 hours completed of
382 (100%)
Task
Plan Start
Plan Hrs
Started
Completed
Actual Hrs
Build table
2011-12-30
30
2012-04-08
2012-04-13
18
Tack bottom tubes
2012-01-05
10
2012-04-14
2012-04-15
12
Tack nose
2012-01-09
16
2011-11-27
2012-04-11
16
Tack upper tubes
2012-01-15
38
2012-04-15
2012-04-23
28
Tack rear tubes
2012-01-25
24
2012-04-27
2012-07-09
14
Tack diagonals
2012-01-30
14
2012-05-12
2012-05-23
12
Tack transmission tunnel
2012-02-03
32
2012-04-23
2012-04-27
22
Tack Aussie mods
2012-02-11
16
2012-06-29
2012-07-06
6
Fully weld frame
2012-02-13
24
2012-04-28
2012-07-24
38
Suspension brackets
2012-02-27
14
2012-05-14
2012-05-27
16
Engine mounts
2012-03-03
20
2012-08-05
2012-11-09
24
Brake line brackets
2012-03-12
4
2012-08-19
2012-08-19
2
Handbrake mount
2012-03-13
4
2012-04-25
2012-05-11
2
Seatbelt brackets
2012-03-13
6
2012-05-25
2012-05-25
4
Wheel arches
2012-03-15
8
2012-08-26
2012-12-01
10
Fuel tank brackets
2012-03-18
4
2012-07-09
2012-07-09
2
Firewalls
2012-03-19
12
2012-09-26
2012-11-27
12
Floor
2012-03-23
24
2012-08-29
2012-11-30
26
Shock mounts
2012-04-02
18
2012-06-22
2012-06-22
10
Steering mounts
2012-04-05
28
2012-06-06
2012-07-11
28
Roll bar
2012-04-15
18
2012-12-10
2013-01-01
24
Cap tubes
2012-04-24
12
2012-11-09
2012-11-10
10
Sand welds
2012-04-27
16
2012-11-03
2013-02-15
14
Paint frame
2012-05-02
28
2013-02-15
2013-03-10
32
Build
Step #4: Front suspension
188 hours completed of
188 (100%)
Task
Plan Start
Plan Hrs
Started
Completed
Actual Hrs
Build jigs
2012-05-14
20
2011-09-21
2011-11-12
44
Cut upper A-arm tubes
2012-05-29
22
2011-09-24
2011-10-30
32
Tap upper A-arm tubes
2012-06-10
4
2011-10-01
2011-11-13
12
Cut lower A-arm tubes
2012-06-14
16
2011-09-24
2011-11-13
12
Cut lower A-arm brackets
2012-06-18
34
2011-10-15
2011-11-27
46
Weld upper A-arms
2012-07-05
12
2011-12-29
2012-01-14
12
Weld lower A-arms
2012-07-09
12
2011-12-29
2012-01-17
12
Paint A-arms
2012-07-13
12
2012-05-06
2012-05-16
8
Attach A-arms
2012-07-16
24
2012-05-14
2012-05-29
10
Build
Step #5: Rear suspension
140 hours completed of
140 (100%)
Task
Plan Start
Plan Hrs
Started
Completed
Actual Hrs
Cut trailing arms
2012-07-20
14
2012-01-04
2012-01-13
12
Cut Panhard rod
2012-07-24
4
2012-01-04
2012-01-14
4
Cut diff brackets
2012-07-25
32
2012-01-14
2012-02-21
32
Clean differential
2012-08-06
16
2012-07-21
2012-09-03
10
Weld trailing arms
2012-08-09
8
2012-07-13
2012-07-20
4
Weld Panhard rod
2012-08-11
2
2012-07-20
2012-07-20
2
Weld diff brackets
2012-08-12
34
2012-04-11
2012-09-12
38
Assemble differential
2012-08-25
10
2012-07-22
2013-03-17
10
Paint differential
2012-08-29
10
2013-02-09
2013-02-23
10
Attach differential
2012-09-01
18
2012-07-22
2013-03-17
18
Build
Step #6: Steering
16 hours completed of
16 (100%)
Task
Plan Start
Plan Hrs
Started
Completed
Actual Hrs
Mount rack
2012-09-08
10
2012-07-07
2012-07-12
4
Mount column
2012-09-09
22
2012-03-26
2012-08-24
12
Build
Step #7: Brakes
110 hours completed of
110 (100%)
Task
Plan Start
Plan Hrs
Started
Completed
Actual Hrs
Install pedal box
2012-09-13
20
2012-03-07
2012-06-19
42
Master cylinder
2012-09-28
4
2013-02-09
2013-03-13
4
Route brake lines
2012-09-30
18
2012-07-15
2013-04-12
16
Install backing plates
2012-10-05
10
2012-09-10
2013-03-16
10
Install hubs
2012-10-09
8
2012-09-10
2012-09-14
8
Install calipers
2012-10-12
8
2012-07-15
2012-09-14
6
Install shoes
2012-10-14
4
2012-09-17
2013-03-17
4
Install flex lines
2012-10-15
2
2013-03-18
2013-03-18
2
Bleed system
2012-10-16
4
2013-04-12
2013-04-16
4
Install handbrake
2012-10-18
14
2012-07-09
2012-09-26
14
Build
Step #8: Drive train
104 hours completed of
104 (100%)
Task
Plan Start
Plan Hrs
Started
Completed
Actual Hrs
Clean transmission
2012-10-23
10
2012-03-12
2013-02-18
10
Install transmission
2012-10-26
16
2012-08-31
2013-04-19
16
Clean engine
2012-11-01
16
2012-01-21
2013-02-23
16
Install engine
2012-11-06
18
2012-08-31
2013-04-13
14
Install intake
2012-11-11
8
2013-04-14
2013-04-16
6
Install controls
2012-11-14
8
2013-03-21
2013-04-18
8
Install accessories
2012-11-16
6
2012-10-06
2013-04-18
4
Install clutch
2012-11-18
24
2012-09-22
2013-04-10
24
Install driveshaft
2012-11-26
8
2013-08-30
2013-09-04
6
Build
Step #9: Fuel system
56 hours completed of
56 (100%)
Task
Plan Start
Plan Hrs
Started
Completed
Actual Hrs
Install tank
2012-11-29
20
2012-12-07
2013-05-20
20
Install pump
2012-12-06
8
2012-03-28
2012-07-25
8
Route lines
2012-12-09
28
2012-11-12
2013-05-19
28
Build
Step #10: Cooling system
32 hours completed of
32 (100%)
Task
Plan Start
Plan Hrs
Started
Completed
Actual Hrs
Install radiator
2012-12-19
10
2012-02-24
2012-07-14
8
Attach hoses
2012-12-21
16
2012-09-25
2012-09-28
8
Attach fan
2012-12-24
18
2013-06-02
2013-07-07
16
Build
Step #11: Electrical
60 hours completed of
60 (100%)
Task
Plan Start
Plan Hrs
Started
Completed
Actual Hrs
Install harness
2012-12-30
42
2012-11-11
2013-05-26
40
Mount fuse box
2013-01-13
6
2012-12-05
2012-12-05
4
Mount battery
2013-01-15
6
2013-04-26
2013-08-26
6
Install starter
2013-01-17
4
2013-04-14
2013-04-14
2
Connect fuel system
2013-01-17
6
2013-03-30
2013-03-31
4
Connect drive train
2013-01-19
6
2013-04-17
2013-05-16
4
Build
Step #12: Exhaust
38 hours completed of
38 (100%)
Task
Plan Start
Plan Hrs
Started
Completed
Actual Hrs
Cut tubes
2013-01-20
20
2012-09-23
2012-10-21
10
Bend tubes
2013-01-24
12
2012-10-06
2012-10-21
4
Weld tubes
2013-01-25
8
2012-10-03
2012-11-08
8
Attach muffler
2013-01-28
8
2012-10-17
2012-10-21
4
Attach hangers
2013-01-30
16
2012-10-17
2012-10-24
6
Heat shield
2013-02-01
10
2013-06-04
2013-08-28
6
Build
Step #13: Interior
310 hours completed of
310 (100%)
Task
Plan Start
Plan Hrs
Started
Completed
Actual Hrs
Scuttle
2013-02-03
70
2012-07-20
2013-02-02
70
Sheet trans tunnel
2013-02-28
38
2012-09-23
2012-12-19
42
Sheet rear bulkhead
2013-03-15
30
2012-09-23
2013-05-26
30
Build dashboard
2013-03-25
30
2012-09-28
2013-05-11
34
Attach dashboard
2013-04-07
10
2013-03-24
2013-05-26
10
Install gauges
2013-04-10
16
2013-03-27
2013-06-23
16
Install switches
2013-04-16
8
2013-05-04
2013-06-23
8
Install glovebox
2013-04-19
22
2013-04-01
2013-05-08
22
Fit mirrors
2013-04-27
4
2013-03-04
2013-08-26
2
Fit carpeting
2013-04-27
6
2013-07-10
2013-07-21
8
Fit interior panels
2013-04-30
16
2013-06-23
2013-07-22
16
Attach steering wheel
2013-05-06
4
2013-03-21
2013-04-17
2
Build seats
2013-05-07
22
2013-06-01
2013-09-22
24
Install seats
2013-05-15
26
2013-01-19
2013-09-22
26
Build
Step #14: Exterior
214 hours completed of
214 (100%)
Task
Plan Start
Plan Hrs
Started
Completed
Actual Hrs
Panel bottom front
2013-05-24
6
2013-03-06
2013-03-08
6
Panel trunk area
2013-05-26
28
2013-04-21
2013-07-13
18
Paint rear panel
2013-06-02
4
2013-07-14
2013-08-03
4
Panel sides
2013-06-03
20
2013-05-29
2013-08-17
20
Paint side panels
2013-06-10
4
2013-07-14
2013-08-03
4
Front panels
2013-06-12
26
2013-06-14
2013-08-18
26
Paint front panels
2013-06-21
4
2013-07-15
2013-08-03
2
Fit nose cone
2013-06-22
14
2012-07-26
2012-08-19
18
Grill
2013-06-28
24
2013-07-29
2013-08-27
24
Build bonnet
2013-07-07
30
2013-03-29
2013-07-17
28
Paint bonnet
2013-07-17
4
2013-07-21
2013-08-03
2
Build fender mounts
2013-07-18
16
2013-08-19
2013-09-21
18
Attach front fenders
2013-07-24
10
2013-09-21
2013-09-30
10
Attach rear fenders
2013-07-28
10
2013-06-26
2013-07-04
12
Spare tire carrier
2013-08-01
22
2012-07-11
2012-10-12
22
Build
Step #15: Lighting
76 hours completed of
76 (100%)
Task
Plan Start
Plan Hrs
Started
Completed
Actual Hrs
Build headlight bar
2013-08-09
20
2012-12-08
2013-03-10
16
Attach headlights
2013-08-14
12
2013-06-21
2013-08-09
12
Attach tail lights
2013-08-19
8
2013-06-28
2013-08-14
6
Attach running lights
2013-08-21
44
2013-05-29
0000-00-00
42
Build
Step #16: Windshield
50 hours completed of
50 (100%)
Task
Plan Start
Plan Hrs
Started
Completed
Actual Hrs
Install defroster vents
2013-09-05
14
2013-02-09
2013-08-18
14
Assemble windshield
2013-09-10
12
2013-09-08
2013-09-22
12
Install windshield
2013-09-14
6
2013-09-25
2013-09-30
4
Install wipers
2013-09-15
18
2013-09-13
2013-10-13
20
Build
Step #17: Final assembly
28 hours completed of
28 (100%)
Task
Plan Start
Plan Hrs
Started
Completed
Actual Hrs
Install mirrors
2013-09-23
8
2013-08-25
2013-09-01
8
Install seat belts
2013-09-25
10
2013-01-11
2013-09-28
10
Install spare tire
2013-09-29
2
2013-08-14
2013-08-20
2
Install shocks
2013-09-30
8
2013-09-25
2013-09-27
8
About
Our Locost Our Build Plan Building a Locost Build Summary Workshop Manual Construction Manual
Our Build Log
Phase I - First Steps Construction Begins | August 1, 2011 Suspension Ideas | August 21, 2011 New Tools | September 3, 2011 Vacation Note | September 21, 2011 Suspension Work | October 1, 2011 Tapping | October 6, 2011 The New Jig | October 20, 2011 Drawing Board | October 24, 2011 New and Improved | October 31, 2011 Tap Lessons | November 6, 2011 The First Setback | November 9, 2011 Suspension Progress | November 12, 2011 The Plan | November 15, 2011 Suspension Brackets | November 17, 2011 Safety | November 21, 2011 The Nose Jig | November 28, 2011 Bushings | November 30, 2011 Frame Tubes | December 5, 2011 Inspiration | December 13, 2011 The Donor | December 19, 2011 Suspension Milestone | December 31, 2011 Rear Suspension | January 4, 2012 Frame Space | January 11, 2012
Phase II - The Donor The Donor Arrives | January 14, 2012 Engine Work | January 19, 2012 Donor Woes | January 28, 2012 The Donor Lives | February 5, 2012 Back to Basics | February 11, 2012 Donor Thoughts | February 22, 2012 Radiator Testing | February 26, 2012 Last Drive of the Donor | March 1, 2012 Fitting the Engine | March 5, 2012 Restoring Parts | March 9, 2012 Dismantling the Donor | March 12, 2012 Pedal Box Engineering | March 18, 2012 Donor Milestone | March 23, 2012 Back to Building | March 27, 2012
Phase III - The Frame Thoughts on Welding | April 5, 2012 First Actual Welding | April 11, 2012 Frame Building Begins | April 16, 2012 Frame Progress | April 20, 2012 The R-word | April 24, 2012 Transmission Tunnel | April 27, 2012 Frame Welding | April 30, 2012 Welding Continues | May 3, 2012 First Welding Setback | May 7, 2012 Basic Frame Completed | May 11, 2012 Suspension Brackets | May 15, 2012 Measure Twice | May 18, 2012 Back on Track | May 21, 2012 Chassis Details | May 26, 2012
Phase IV - Getting it Rolling Pedal Issues | May 31, 2012 Steering Column | June 4, 2012 Steering Column Issues | June 9, 2012 Pedals are In | June 15, 2012 Suspension Progress | June 21, 2012 Aussie Mods | June 26, 2012 Installing the Radiator | June 30, 2012 Steering Directions | July 3, 2012 Last Frame Tubes | July 8, 2012 More Chassis Details | July 12, 2012 Putting on the Brakes | July 16, 2012 Nuts | July 21, 2012 Last of the Welding | July 26, 2012 One Year Ago | July 29, 2012 Framing the Scuttle | August 3, 2012 Panhard Setback | August 8, 2012 Grinding | August 12, 2012 Two Steps Forward | August 17, 2012 Scuttle Work | August 21, 2012 Steering Connections | August 25, 2012 The Build Table | August 29, 2012 Engine Installation | September 4, 2012 Restoration Work | September 10, 2012 Suspension Install | September 15, 2012 Chassis Assembly | September 19, 2012 Roller | September 23, 2012
Phase V - Getting it Running Handbrake | September 26, 2012 Exhaust Ideas | September 29, 2012 Cooling | October 3, 2012 Dashboard Ideas | October 7, 2012 More Brackets | October 12, 2012 More Sheeting | October 16, 2012 Exhaust Work | October 21, 2012 Scuttle Parts | October 25, 2012 Tunnel Panels | October 29, 2012 Engine Removal | November 4, 2012 Welding Limits | November 8, 2012 Wiring Ideas | November 12, 2012 Tabs Everywhere | November 16, 2012 Sheet Metal | November 21, 2012 Firewalls | November 26, 2012 The Floor | November 30, 2012 Final Chassis Details | December 5, 2012 Little Projects | December 12, 2012 Lighting | December 19, 2012 Roll Bar | December 23, 2012 Wind Buffeting | December 29, 2012 Lowering the Bar | January 3, 2013 Weather Watch | January 8, 2013 Waiting Game | January 12, 2013 Aluminum Work | January 17, 2013 Seats | January 23, 2013 Dashboard Mount | January 28, 2013 Last of the Welding | February 2, 2013 More Pedals | February 7, 2013 Month of Painting | February 12, 2013 A Painted Chassis | February 17, 2013 Defrosting | February 22, 2013 Last of the Painting | February 27, 2013 Chassis Prep | March 4, 2013 Final Assembly | March 8, 2013 Brake Lines | March 12, 2013 Back on Wheels | March 17, 2013 Counting Down | March 22, 2013 Aluminum dashboard | March 27, 2013 Wiring Begins | March 31, 2013 Transmission | April 4, 2013 Bonnet | April 8, 2013 Drivetrain | April 13, 2013 Last Minute Items | April 17, 2013 Runner | April 19, 2013
Phase VI - Coachwork Project Thoughts | April 24, 2013 Glove Box | April 29, 2013 Tuning | May 4, 2013 Final Plan | May 8, 2013 Veneering | May 12, 2013 Color Issues | May 16, 2013 Fuel System | May 20, 2013 Electricity | May 24, 2013 Building the Body | May 28, 2013 Lighting | June 1, 2013 Seating Positions | June 5, 2013 Bending Aluminum | June 10, 2013 Fitting Panels | June 15, 2013 Cooling | June 20, 2013 Headlights | June 24, 2013 Wings | June 29, 2013 Paint Prep | July 3, 2013 Interior Bits | July 8, 2013 Gray Primer | July 14, 2013 90% and Counting | July 20, 2013 Sanding | July 24, 2013 Year Three | July 29, 2013 Going Green | August 3, 2013 Light Work | August 8, 2013 Grill Work | August 13, 2013 Glossy | August 18, 2013
Phase VII - Getting it Registered Final Details | August 23, 2013 Final Budget | August 28, 2013 Final Entries | September 2, 2013 Propshaft | September 6, 2013 Windshield | September 11, 2013 Electrics | September 16, 2013 Front Fenders | September 20, 2013 Seats | September 24, 2013 First Drive | September 28, 2013 Last Piece | October 3, 2013 Mods | October 8, 2013 Change of Plans | October 13, 2013 Weight | October 19, 2013 Cosmetic Changes | October 26, 2013 Updates | November 3, 2013 Inspections | November 10, 2013 SB100 | November 18, 2013 Almost Official | November 28, 2013 Final Mods | December 7, 2013 Waiting | December 15, 2013 Finally Cool | December 22, 2013 Long Drives | January 1, 2014 Repairs | January 8, 2014 Glove Box Redux | January 15, 2014 Body Work | January 22, 2014 Smog | January 28, 2014 Scoop | February 3, 2014 Brakes & Lights | February 10, 2014 30 Months Later | February 15, 2014
Phase VIII - On the Road First Impressions | June 14, 2014 Commuting | September 12, 2014 Maintenance | October 12, 2014 Upgrades | January 19, 2015 Repairs | April 5, 2015 The Long Miles | May 26, 2015 Another First | June 23, 2015 Tinkering | July 23, 2015 Summer in the City | August 25, 2015 Car Shows | September 23, 2015 The Experiment | October 6, 2015 Superbowl Tour | October 25, 2015 The List | November 14, 2015 M.G. Clutches | November 27, 2015 20K Miles | December 20, 2015 Interior Redo | January 18, 2016 Exterior Redo | January 31, 2016 More Broken Parts | February 12, 2016 Cool Systems | March 31, 2016 Maker Faire Prep | April 29, 2016 Calibration | May 18, 2016 Electric Dreams | May 31, 2016 Structural Integrity | June 12, 2016 Noises | July 2, 2016 New Projects | July 27, 2016 Back to Welding | August 11, 2016 Bonnet 2.0 | August 24, 2016 It's a Wrap | September 5, 2016
Phase IX - Refinements Ten Years Ago | September 17, 2016 Clutch Revisited | September 29, 2016 Little Locosts | October 11, 2016 Stressing | October 25, 2016 Still Welding | November 8, 2016 Wheel Upgrades | January 31, 2017 Deja Suspension | February 26, 2017 Maker Faire Plans | April 30, 2017 Carbs Revisited | May 12, 2017 Wheels Revisted | June 9, 2017 Parts Car | July 3, 2017 Grip | July 24, 2017 Eclipsed | August 24, 2017 Longevity | September 14, 2017 Exhausting | September 27, 2017 Neglect | October 12, 2017 We Have Ignition | November 3, 2017 Exhaust 2.0 | December 4, 2017 Upcoming Projects | March 9, 2018 One Down | March 30, 2018 Still Driving | December 7, 2018 Maker Faire 2019 | March 24, 2019
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